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Here are some pics of a recently arrived Bo Katan helmet (woo hoo!). My kid was excited. I went ahead and did a quick trim of the visor area (thank you dremel). It will need a tad more sanding/trimming in the inside but I think it is a mighty fine helmet. I am thinking for the rest of the build to use a unitard for the main body, then probably a heavy cotton for the vest as suggested in a previous post. I am assuming 3mm sintra is the way to go for the armor plates. My daughter is a tween so I am thinking of doing a standard mando DW pattern for the armor as opposed to giving cups. I know Bo Katan has cups, but then she is also a grown woman (am I too worried about this?). So I guess instead of a Bo Katan she'll be her lesser known little sister, Go Katan (or would No-Go Katan be more appropriate?) Wish me luck!

On the pne I painted up for me, I actually used a couple of really short screws from the inside of the helmet into the earcap portion of the stalk. Youll need to predrill the holes and use a drop or two of loctite.

Well, here is a picture of a unitard I ordered from a local dance shop. It is a Bal Tog mock turtle neck in "gasoline grey". I think it is pretty darn close in color. Its a tad darker in the pic than it really is. For a better description of the color, go to Bal Togs Supplex/Lycra Color Chart

Well, Tony and I finally bit the bullett and dove in on trying to make some body armor for our younglings. We are lucky they are similar in size. I was able to get a hold of sintra from Meyers Plastics. We opted for 3mm. It comes in 48"x96" sheets at less that $30 per sheet. They also cut them to size for me. I had no idea how much we would need so I opted for two sheets which I had them cut into quarters so it could fit in my car. Based on the progress we are making so far, we are going to have a lot of sintra left over.

First we went for the shoulder bells. To help with the curve we used a small plastic dish to trace. This is the the first time either of us had worked with this material so this is a learn as you go project. Tin snips we found if you weren't too careful would easily split/crack/fracture the plastic. A dremel or jig saw is highly recommended.

To get the curve/flare we used a standard spray paint can along with a heat gun. The sintra responded beautifully to the heat and cooled quickly. We think the shoulders turned out GEFG (good enough for government)

From there we moved on to the thigh plates. Here we used the templates generated by DOD and formed them around standard gallon paint cans.

We were starting on the holster parts before we had to call it a night. Hope to make more progress soon!